Socket head attachment system for a baton scabbard

ABSTRACT

A scabbard is provided for a baton. The scabbard includes a baton receiver that receives the baton, a belt clip coupled to the baton receiver and a socket head screw having a socket head and a shaft that attaches the belt clip to the baton receiver. The socket head screw includes the socket head having a relatively large diameter compared to a diameter of the shaft and a socket head recess disposed in the socket head, said socket head recess having a relatively small diameter compared to a diameter of the shaft of the socket head screw, said socket head recess extending through the socket head and extending into the shaft of the socket head screw.

FIELD OF THE INVENTION

The field of the invention relates to scabbards for police batons and more particularly to attachment devices for assembling scabbards used to carry batons.

BACKGROUND OF THE INVENTION

Police and security personnel are often required to carry weapons of intermediate force such as nightsticks or batons. Batons are available in a variety of sizes, usually consisting of three telescoping sections. In the retracted position, an expandable baton is only approximately one-third of its extended length.

In order for a baton to be of maximum utility to the officer or other baton user, it should be able to be carried by the officer at all times while on duty, and without interfering with the mobility of the officer when it is not needed. On the other hand, the baton must be able to be quickly deployed by the officer whenever needed.

When not in use, batons are usually carried in a scabbard that may be attached to a waist belt of the officer. In general, a baton scabbard can be used to enable the efficient use and transport of a baton. The scabbard should allow for a wide range of deployment or withdrawal directions that may be required when in pursuit or subduing a subject. The scabbard should secure the baton to the officer during the officer's daily activities, such as when the officer is pursuing a subject and may be required to run, jump, climb over walls or fences or move quickly up or down stairs. The scabbard should secure the baton in a manner which allows for full body movement by the officer. It should allow the officer to comfortably carry the baton throughout the day including when the officer is standing or sitting.

U.S. Pat. No. 6,889,878 to Parsons, assigned to the assignee of the present invention, is an example of a baton scabbard that substantially meets the needs of police officers. While Parsons is effective, it is also relatively complex to construct. Because of the importance of the safety of police officers a need exists for a baton scabbard that has the functionality of Parsons, but is less complex and easier to manufacture.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of a baton scabbard in accordance with an illustrated embodiment of the invention;

FIG. 2 is an exploded view of the belt clip assembly of FIG. 1;

FIG. 3 is a front, perspective view of the closed-loop belt clip of FIG. 1;

FIG. 4 is a front view of the baton scabbard of FIG. 1 with the belt clip assembly being show rotated into alternate positions;

FIG. 5 is a side view of the scabbard of FIG. 1 showing a belt of a user in phantom;

FIG. 6 is a side cut-away view of the scabbard of FIG. 5;

FIG. 7 is a top, perspective view of the scabbard of FIG. 1;

FIG. 8 is a side view of the scabbard of FIG. 1;

FIG. 9 is a rear, perspective view of the scabbard receiver of FIG. 1;

FIG. 10 are views of opposing, mating structures of FIG. 1 including a back view of the belt clip assembly, shown on the left and a back view of the receiver shown on the right; and

FIG. 11 is an end and side view of a socket head screw that may be used with the scabbard of FIG. 1.

SUMMARY

A scabbard is provided for a baton. The scabbard includes a baton receiver that receives the baton, a belt clip coupled to the baton receiver and a socket head screw having a socket head and a shaft that attaches the belt clip to the baton receiver. The socket head screw includes the socket head having a relatively large diameter compared to a diameter of the shaft and a socket head recess disposed in the socket head, said socket head recess having a relatively small diameter compared to a diameter of the shaft of the socket head screw, said socket head recess extending through the socket head and extending into the shaft of the socket head screw.

DETAILED DESCRIPTION OF AN ILLUSTRATED EMBODIMENT

FIG. 1 is a front perspective view of a low-profile support structure (e.g., a baton scabbard) 10 shown generally in accordance with an illustrated embodiment of the invention. Also shown in FIG. 1 is a baton 12 (shown in phantom) disposed within the scabbard 10.

The scabbard 10 includes a baton receiver 14 and a belt clip assembly 16. The receiver 14 is constructed of a relatively thin, lightweight tubular body 18 (FIG. 5) that is substantially continuous in the axial and annular directions. The tubular body 18 may be fabricated of any appropriate light weight material (e.g., plastic, delrin, acetel, polycarbonate, etc.).

The upper portion of the tubular body 18 (adjacent the belt clip assembly 16) may be provided with a slanted top 19 (FIG. 5). The slanted top 19 may be slanted downward on an outside of the receiver 14 from horizontal by some appropriate angle 17 (e.g., eight degrees) to facilitate easy insertion of the baton 12 into the scabbard 10.

The tubular body 18 may also include a baton stop tab 36 (FIG. 9) disposed along a lower, second end of the tubular body 18. The baton stop tab 36 extends inwardly from the tubular body 18 towards a center of the annulus of the tubular body 18. The baton stop tab 36 is of such size as to leave a distance 38 that is sufficient to allow a distal end of the baton 12 to pass through, but insufficient to allow a second end (handle) of the baton 12 to pass through.

The use of the stop tab 36 allows the scabbard 10 to receive the baton 12 in either the extended or retracted state. In the retracted state, the baton 12 may be received within the scabbard 10 as shown in FIG. 1. In the extended state, a first and second sections of the baton 12 may extend past the stop tab 36 with only the upper handle portion contained within the tubular body 18.

The receiver 14 includes a substrate (e.g., a mounting flange) 20 (FIG. 9). Under one preferred embodiment, the mounting flange is an extension of the wall of the tubular body 20 that forms a relatively flat surface. The relatively flat surface is substantially tangent to the tubular body 18.

The mounting flange 20 may be formed as an integral part of the tubular body 18 using some appropriate process (e.g., injection molding, ultrasonic welding, etc.). Under another preferred embodiment, the mounting flange 20 may be formed separately and attached to the tubular body 18 by attachment devices (e.g., screws, rivets, etc.).

Disposed on an outside surface of the mounting flange 20 is an unobstructed peripheral mounting surface (flange surface) 22 for the belt clip assembly 16. The peripheral mounting surface is unobstructed because it doesn't have sides extending upwards from the outside edge of the mounting surface 22 that would otherwise make the mounting surface wider than necessary. The peripheral mounting surface 22 lies within a single plane that is substantially tangent to an outer surface of the tubular body 18. The peripheral surface 22 may form a continuous surface around the periphery of the flange 20, as shown in FIG. 9, or may be discontinuous in some areas around the periphery.

Located within the peripheral mounting surface 22 may be one or more apertures 24, 26, 28. The center aperture 26 may extend between the plane of the peripheral mounting surface 22 and the interior of the tubular body 18, as may be more clearly seen in FIGS. 6 and 10.

Disposed within the center aperture 26 may be a leaf spring 30. The spring 30 may have a continuously curved center portion (FIGS. 6 and 7) that engages and secures the baton 12 within the tubular body 18 of the scabbard 10. The continuously curved center portion has been found to allow much easier insertion and removal of the baton from scabbard 10. A post 32 on the flange 20 may engage an aperture 34 within the leaf spring 30 to hold the spring 30 in the proper, operational position.

FIG. 2 shows an exploded view of the belt clip assembly 16. The belt clip assembly 16 may include a belt clip mounting plate 40 fabricated of a relatively soft material (e.g., plastic) and a closed-loop belt clip 42. The belt clip mounting plate 40 may also include a peripheral mounting surface (clip surface) 44 that is complementary to the peripheral mounting surface 22 of the flange 20. Complementary in this case means that the clip mounting surface 44 has substantially the same shape and lies in the same plane as the flange surface 22 during use.

Disposed along an inside edge of clip surface 44 is a projecting ridge 46. The projecting ridge 46 functions as an alignment mechanism for the mechanical junction between the receiver 14 to belt clip assembly 16.

Attachment of the belt clip assembly 16 to the flange 20 may be accomplished via the aid of the ridges 46 and an attachment mechanism. In one preferred embodiment, a set of metal bosses 48, 50, 52 (FIG. 9), each with a female thread 54, may be ultrasonically welded into apertures disposed within the flange surface 22. A complementary set of apertures 54, 58, 60 allow the relatively soft material of the belt clip mounting plate 40 to be secured to the substrate provided by the flange 20 via screws 62, 64, 66 that engage the bosses 48, 50, 52 through the belt clip mounting plate 40.

The closed-loop belt clip 42 may be secured to the belt clip mounting plate 40 via a post 68 that extends through an aperture 70 in the belt clip mounting plate 40. Once the post 68 has been inserted through the aperture 70 a suitable circular push-on external retaining ring 76 (e.g., available from Truarc Manufacturing Co.) may be disposed on a protruding end of the post 68. A set of wave washers 72, 74 between the retaining ring 76 and belt clip mounting plate 40 may urge the closed-loop belt clip 42 and belt clip retaining plate 40 into contact.

Disposed between the belt clip mounting plate 40 and closed-loop belt clip 42 are a series of respective ridges 76 and slots 78 disposed on respective sides of the belt clip mounting plate 40 and closed-loop belt clip 42 and extending radially outwards from the post 68. The ridges 78 and slots 80 are complementary in that the ridges 78 are sized to fit into the slots 80 to retain a selected position.

The receiver 14 is rotatable with respect to the belt clip assembly 16. To select a different orientation between the receiver 14 and belt clip assembly 16, user may simply install the scabbard 10 on his belt 82, grasp and rotate the receiver 14 to a desired position. As the user rotates the receiver 14, the interaction of the tapered edges of the ridges 78 and slots 80 cause the wave washers 72, 74 to compress thereby releasing the receiver 14 to rotate to a new position where the ridges 78 may engage new slots 80.

The closed-loop belt clip 42, as shown in FIGS. 1, 2, 3, 5, 6 and 8 has a belt space 84 that completely encircles the belt 82. Disposed within the belt space 84 is an adjustable spacer 86. A pair of slots 87 extend along a wall of the closed-loop belt clip 42 in a direction across a width of the belt (i.e., transverse to a direction of the belt 84). A pair of screws 92, 94 may engage the spacer 86 through the slots 87. By loosening the screws 92, 94, the spacer 86 can be moved vertically to accommodate any width belt worn by a user.

Disposed between the belt clip plate 40 and the closed-loop clip 42 may be an allen wrench 88 held within an allen wrench slot 90 (FIGS. 2 and 3). In order to facilitate easy adjustment of the spacer 86 or assembly or disassembly (and replacement of parts), screws 62, 64, 66, 92, 94 may all be allen screws of a single size that are removable through use of the wrench 88.

The allen wrench 88 may be inaccessible when the scabbard 10 is in the position shown in FIG. 1. Not only is the allen wrench 88 inaccessible in the position shown in FIG. 1, but the allen wrench 88 cannot fall or and be lost while the scabbard 10 is in the position shown in FIG. 1. Access to the allen wrench 88 and removal from the scabbard 10 may be accomplished by rotating the receiver 14 to the position shown by the solid lines in FIG. 4.

The belt clip assembly 16 may be assembled to the receiver 14 by bringing the flange surface 22 into proximate contact with the clip surface 44 (FIG. 8). Final alignment of the flange surface 22 to the clip surface 44 occurs when the ridge 46 enters the apertures 24, 28 and engages the inner edge of the flange peripheral mounting surface 22.

When the flange surface 22 is aligned with the clip surface 44 the apertures 56, 58, 60 are complementary to the bosses 48, 50, 52 in that the apertures 56, 58, 60 lie directly above the threaded bosses 48, 50, 52. The belt clip assembly 16 may then be secured to the receiver 14 via screws 62, 64, 66.

Once the belt clip assembly 16 has been secured to the receiver 14, the ridges 46 contact and slightly deform upon contacting the inner edge of the flange surface 22, thereby establishing an interference fit between the flange 20 and belt clip assembly 16. The interference fit prevents lateral movement between the belt clip assembly 16 and receiver 14. In addition, the relatively large surface area of the flange surface 22 and complementary clip surface 44 distributes the direct and shock loading of use over a relatively large surface area.

The ridge 46 eliminates any lateral loading on the screws 62, 64, 66. The screws 62, 64, 66 are therefore subject exclusively to axial loading. The relatively large surface area of the flange surface 22 and clip surface 44 reduces the force per unit area (lbs/in²) to a relatively low level.

The distribution of forces over a relatively large area allows the mounting flange 22 to be reduced in size and to occupy only a portion of the length of the receiver 14. As shown in the figures, the mounting flange 22 occupies an area of less than one-half of the length of the receiver 14.

In another embodiment of the invention, the screws 62, 64, 66 are socket head screws that are specially adapted for support structures, such as the baton scabbard 10 and similar applications. As noted above, the belt clip mounting plate 40 may be fabricated of plastic. The plastic material of the belt clip mounting plate 40 represents a relatively soft material that must be mounted to a substrate (i.e., the mounting flange 20). The relative softness of the plastic causes a situation where a conventional metal screw head would easily pull through the surrounding plastic of the apertures 56, 58, 60. Alternatively, if the screws 62, 64, 66 were to be tightened too much, the bosses 48, 50, 52 will pull free of the plastic material of the flange 20. In order to avoid these problems, the socket head screws 62, 64, 66 are provided with a number of distinguishing features.

FIG. 11 shows a side, partially cut-away view of the socket head screws 62, 64, 66. As shown in FIG. 11, the screws 62, 64, 66 include a head portion 100 and a shaft (threaded portion) 102. The head portion 100 may be provided with a relatively large socket head 104. Relatively large, in this context, means that the diameter A of the head 104 is at least twice as large as a diameter D of the shaft 102. In one preferred embodiment, the diameter A of the head 104 is at least three times the diameter D of the shaft 102.

In addition to having a relatively large diameter head 104, the head 104 also has a depth H measured along a predominant (longitudinal) axis 108 of the screw 62, 64, 66 that is relatively thin. A relatively thin head depth means that the depth of the head H is less than 75% of the diameter D of the shaft 102.

The use of screws 62, 64, 66 with a relatively large head diameter allows for the use of a larger shaft 102 (as measured by a diameter D) than would otherwise be possible without the risk of pull-out. In order to further optimize the use of larger diameter screw portions 102, the apertures 56, 58, 60 may be provided with recesses 67 in the belt clip mounting plate 40. The recesses 67 are provided with a diameter slightly larger than the diameter A of the screw head 104 and with a depth that is slightly greater than a depth H of the screw head 104. The result is that the heads 104 of the screws 62, 64, 66 do not protrude out of the recesses 67 thereby allowing the closed-loop belt clip 42 to rotate freely without the heads 104 interfering with the rotation.

For a number of reasons (discussed below), the screws 62, 64, 66 may also be provided with a relatively small hex (alien) wrench aperture 106. A relatively small wrench aperture 106 means that a diameter J of the aperture 106 is less than 75% of the diameter D of the screw portion (shaft) 102.

It should be noted that because of the relatively thin depth H of the screw head 104, the aperture 106 extends through the head portion 100 into a portion 110 of the shaft 102 where the shaft 102 abuts the head portion 100. More specifically, the depth T of the recess 106 exceeds the screw head depth H. The depth T may be determined by squaring a diameter D of the screw portion 108 and dividing by two times the diameter J of the recess 106. A proportionality factor may also be applied to the result to accommodate the relative hardness of the screws 62, 64, 66.

The relatively small diameter J of the recess 106 may be used in combination with the depth T of the recess 106 to limit the torque that may be applied to the screw 62, 64, 66. In this regard, the diameter J and depth T may be controlled to allow the allen wrench to break before the bosses 48, 50, 52 pull out of the flange 20.

In general, the diameter J of the wrench recess 106 may be a consideration in choosing the depth H of the screw head 104. It should be noted in this regard that if a conventional wrench size aperture were chosen based upon the diameter D of the shaft 102, then the thickness of the intervening wall 112 that connects the head portion 100 and shaft 102 would not be of sufficient thickness and strength to resist shearing forces and failure. In accordance with illustrated embodiments, a single relatively small wrench diameter J is selected to accommodate all of the screws 62, 64, 66, 92, 94 within the scabbard 10 based upon the loading of the screws 62, 64, 66, 92, 94. The depth T of the recess 106 may be adjusted according to the force on the screws 62, 64, 66, 92, 94 and the requirement that the allen wrench fail before damage occurs to the screw head recess 106. In general, the hex wrench 88 within the recess 90 is provided to accommodate that diameter J chosen for the screws 62, 64, 66, 92, 94.

A specific embodiment of a baton scabbard has been described for the purpose of illustrating the manner in which the invention is made and used. It should be understood that the implementation of other variations and modifications of the invention and its various aspects will be apparent to one skilled in the art, and that the invention is not limited by the specific embodiments described. Therefore, it is contemplated to cover the present invention and any and all modifications, variations, or equivalents that fall within the true spirit and scope of the basic underlying principles disclosed and claimed herein. 

1. A scabbard for a baton comprising: a baton receiver that receives the baton; a belt clip coupled to the baton receiver; and a socket head screw having a socket head and a shaft that attaches the belt clip to the baton receiver, said socket head screw further comprising the socket head having a relatively large diameter compared to a diameter of the shaft; and a socket head recess disposed in the socket head, said socket head recess having a relatively small diameter compared to a diameter of the shaft of the socket head screw, said socket head recess extending through the socket head and extending into the shaft of the socket head screw.
 2. The scabbard as in claim 1 wherein the relatively large socket head further comprises a diameter that is at least twice as large as a diameter of the shaft of the socket head screw.
 3. The scabbard as in claim 1 wherein the relatively large socket head further comprises a diameter that is at least three times larger than a diameter of the shaft of the socket head screw.
 4. The scabbard as in claim 1 wherein the relatively large socket head further comprises a depth, measured along a predominant axis of the shaft, that is at least twenty-five percent less than a diameter of the shaft.
 5. The scabbard as in claim 1 wherein the socket head recess has a diameter that is at least twenty-five percent less than a diameter of the shaft.
 6. The scabbard as in claim 1 wherein the receiver further comprises a tubular body that is substantially continuous in an annular and axial direction and a mounting flange disposed on an outer surface of the tubular body proximate a first end of the tubular body, said mounting flange defined by an unobstructed planar mounting surface substantially surrounding a center aperture, said planar mounting surface being substantially tangent to an outer surface of the tubular body.
 7. The scabbard as in claim 6 further comprises a belt clip mounting plate with a peripheral mounting surface that is complementary to the unobstructed mounting surface that couples the belt clip to the baton receiver.
 8. The scabbard as in claim 7 further comprising a plurality of threaded bosses disposed within the unobstructed mounting surface.
 9. The scabbard as in claim 8 wherein the socket head screw further comprises a plurality of socket head screws that engage the threaded bosses through a corresponding plurality of apertures in the belt clip mounting plate of the belt clip assembly to detachably secure the belt clip mounting plate to the mounting flange.
 10. The scabbard as in claim 9 wherein the belt clip mounting plate further comprises plastic.
 11. The scabbard as in claim 10 wherein the belt clip mounting plate further comprises a plurality of screw head recesses adapted to receive the relatively large socket heads so that the relatively large socket heads do not protrude from the recesses.
 12. A support structure comprising: a substrate; a relatively soft material; a socket head screw having a socket head and a shaft adapted to attach the relatively soft material to the substrate, said socket head having a relatively large diameter compared to a diameter of the shaft; and a socket head recess disposed in the socket head, said socket head recess having a relatively small diameter compared to a diameter of the shaft of the socket head screw, said socket head recess extending through the socket head and into the shaft of the socket head screw.
 13. The socket head screw system as in claim 12 wherein the support structure further comprises a baton scabbard, the relatively soft material further comprises a belt clip of the baton scabbard and the substrate further comprises a baton receiver of the baton scabbard.
 14. The socket head screw system as in claim 13 wherein the relatively large screw head is at least twice as large as the screw portion of the socket head screw.
 15. The scabbard as in claim 12 wherein the relatively large socket head further comprises a depth, measured along a predominant axis of the shaft, that is at least twenty-five percent less than a diameter of the shaft.
 16. The socket head screw system as in claim 12 wherein the relatively small diameter socket head recess further comprises a socket head recess diameter that is less than three quarters a diameter of the shaft of the socket head screw.
 17. The scabbard as in claim 12 wherein the relatively soft material further comprises plastic. 